STR No.

MC/STR/W/03 –Rev-1

Government of India
Ministry of Railways

Schedule of Technical Requirements

for Infrastructural, Manufacturing & Testing Facilities
and Quality Control

For
Wire and Flux for Submerged Arc Welding as per IRS- M: 39 -
2001(With Amendment No. 1&2)

Metallurgical & Chemical Directorate

Research Designs & Standards Organisation
Manak Nagar, Lucknow – 226011

21.03.2011
 2

1.0 SCOPE
This schedule covers the technical requirements for manufacture of Wire and Flux
for Submerged Arc Welding (SAW) as per IRS–M–39-01.

1.1 The welding consumables for submerged arc welding have been grouped as below
on the basis of infrastructure facilities, manufacturing process, quality control and
application at users end.

Group VIII A SAW Wire, Class W1, W2 , W3 , W4 , W5

Group VIII B SAW Flux, Class F1, F2 , F3 , F4 , F5

1.2 FRESH APPROVAL :

The firms seeking for approval at RDSO shall apply a minimum of following
classes in each groups and will have to qualify all the items of applied group:

Group No. Minimum Class applied

Group – VIII A (W1) +(W2 or W3 or W4 or W5)

Group – VII B (F1) +( F2 or F3 or F4 or F5)

1.3 The firm should have the experience of at least three (3) years of manufacturing and
supplying/ exporting the applied welding consumables to the industries
manufacturing earth moving equipments, marine industries and thermal power
plants ( Enclose documentary evidences)
1.4 The firm should have annual turn over of minimum one (1) crore
1.5 The details of Manufacturing & testing facilities shall be submitted in format of
Annexure to STR as per Annex-I
1.6 The details about applied items and its test results as per Annex-III , IV&V

2.0 REQUIREMENTS FOR SAW WIRE ( Class W1, W2 , W3 , W4 , W5 )

2.1 GENERAL
2.1.1 The firm should have well illuminated and ventilated covered shed with sufficient
height and space for performing various manufacturing activities like Decoiling,
Wire drawing, Wet wire drawing, Pickling, Washing, Copper Coating, Finished
drawing, Spooling, Packing etc.
2.1.2 Separate identified area for storage of raw materials and finished product and
scraps.
2.1.3 Separate quality control laboratory for physical and chemical testing.

2.1.4 Humidity chamber for storage stability & corrosion test.

 3

2.2 MINIMUM PRODUCTION FACILITIES

The firm should have the following facilities:

2.2.1 Wire drawing and Copper coating facilities consisting of Decoiler, Wire drawing
set, Pickling bath, Washing bath , Coppering bath, Rinsing bath, Finish drawing
and Coiling arrangement

2.2.2 Butt welding machine of suitable capacity for joining wires.

2.2.3 Automatic Spooling machine for winding of wire.
2.2.4 Weighing facilities.
2.2.5 Packing facilities as per clause 4.4 of IRS M-39-01.

2.3 TESTING FACILITIES

2.3.1 GENERAL

2.3.1.1 The firm should have duly calibrated micrometer with least count 0.01mm. for
measurement of diameter of wire.

2.3.1.2 The firm should have arrangement for measurement of copper coating thickness
of wire by colorimeter/wet analysis method.

2.3.1.3 The firm should have SAW (Submerged Arc Welding) machine of capacity
minimum 500 Ampere and nozzle of various sizes for carrying out performance
test of wire.
2.3.2 MECHANICAL TESTING OF WIRE

2.3.2.1 The firm should have one duly calibrated universal testing machine of capacity
5 MT min. for carrying out UTS of finished wire.
2.3.3 CHEMICAL TESTING

2.3.3.1 The firm should have chemical testing laboratory consisting of Carbon-Sulphur
determination apparatus, Chemical balance, Hot plate, Muffle furnace (800ºC),
Electric oven, Barometer, Hygrometer, Platinum crucible, Glass-wares and
Chemicals.
3.0 REQUIREMENTS FOR SUBMERGED ARC WELDING
FLUX(F1,F2,F3,F4,&F5)
3.1 GENERAL
3.1.1 The firm manufacturing agglomerated flux should have well illuminated and
ventilated covered shed with sufficient height and space for various
manufacturing activities consisting of weighing of flux ingredients, Dry mixing,
Wet mixing, Agglomerating, Sieving of final product, Weighing of final flux
product and Packing.
The firm manufacturing fused flux should have well illuminated and ventilated
covered shed with sufficient height and space for various manufacturing activities
 4

consisting of melting in a furnace, quenching, drying, crushing of lump flux,

sieving of final product, weighing and packing.

3.1.2 The firm should have separate identified area for storage of raw material, finished
product and scrap.

3.1.3 The firm should have separate welding room for performance test and test weld
preparations.

3.1.4 The firm should have separate laboratory for physical and chemical testing of raw
material and weld metal.

3.1.5 The firm should have mechanical testing laboratory for carrying out mechanical
test of weld metal.

3.1.6 Machining facilities at same location for preparation of test pieces from weld
assembly

i) Lathe Machine for preparation of All Weld tensile test pieces.

ii) Shaping Machine – for shaping of test pieces, edge preparations on plates & back
gouging of welds.

iii) V-notch cutter with gauge for cutting of V notch on impact test pieces.

iv) Power Hacksaw

3.2 MINIMUM MANUFACTURING FACILITIES

3.2.1 Requirement for Agglomerated Flux

The firm should have following machines/equipment

3.2.1.1 Sieve (B.S. Mesh size 10 or equivalent) for coarse screening of raw material.

3.2.1.2 Dry mixer, capacity 100 Kg. minimum, (generally electrically operated).

3.2.1.3 Wet mixer, capacity 100 Kg. minimum, (generally electrically operated).

3.2.1.4 Drying Oven, 2000C, electrically operated of suitable capacity.

3.2.1.5 Agglomerating Furnace, 6000C of suitable capacity with automatic temperature

control.

3.2.1.6 Sieving set of B.S. mesh size 10, 40, 100 mesh or equivalent for sieving of
finished product.

3.2.1.7 Packing arrangement as per clause 5.6.2 or alternatively as per Clause 5.6.3 of
Amendment 2 of 2005 to IRS- M- 39 –01.
 5

3.2.2 Requirement for fused Flux

The firm should have following machines/equipment
3.2.2.1 Sieve (B.S. Mesh size 10) for coarse screening of raw material.

3.2.2.2 Dry mixer, capacity 100 Kg. minimum, (generally electrically operated).

3.2.2.3 Oil fired/Gas fired/Electric melting furnace, 15000C min. of adequate capacity,
for melting of charged dry mix.

3.2.2.4 Quenching System consisting of Quenching Tanks with arrangement of

continuous flow of water for effective quenching of melted flux.

3.2.2.5 Crushing Arrangement, Gyratory/Jaw crusher to crush the lumps to the required
grain size.

3.2.2.6 Drying oven, 2000C, of suitable capacity for drying of crushed flux.

3.2.2.7 Sieving set of B.S. mesh size 10, 40, 100 mesh or equivalent for sieving of
finished product.

3.2.2.8 Packing arrangement as per clause 5.6.2 or alternatively as per Clause 5.6.3
of Amendment 2 of 2005 to IRS- M- 39 –01.
3.3 TESTING FACILITIES

3.3.1 GENERAL

3.3.1.1 The firm should have facilities for determination of grain size distribution of
flux, measurement of tap density and moisture content of flux.

3.3.1.2 The firm should have facilities for determination of Basicity Index of flux by
XRF method or by Chemical Analysis method.

3.3.1.3 The firm should have SAW machine of capacity 1000 Amp. for performance
test and welding of test weld samples.
3.3.1.4 Radiographic(X –Rays or Gama Rays) test facility( Applicable for firms
applying for radiographic Quality welding consumables)
3.3.1.5 Metallurgical Microscope

3.3.2 MECHANICAL TESTING

3.3.2.1 The firm should have Universal Testing Machine of capacity 20MT min. with
necessary attachment for measuring Yield Load and Breaking Load and
carrying out Bend Test. The machine should be calibrated by a recognized
agency and the firm should have valid calibration certificate.

3.3.2.2 The firm should have duly calibrated Impact Testing Machine capacity
30 kgfm (Charpy ‘V’ notch type test piece) with testing facilities at room
temperature, 0ºC, -20ºC and -46ºC depending upon the requirement of the
product offered.
 6

3.3.3 CHEMICAL TESTING

3.3.3.1 The firm should have chemical testing laboratory for chemical analysis of raw
materials and weld metal.
3.3.5.2 The chemical laboratory should consist of Carbon-Sulphur determination
apparatus, chemical balance, hot plate, muffle furnace (800ºC), electric oven,
barometer, hygrometer, platinum crucible, glass wares and chemicals.
Note: Use of Spectrometer or any other modern facilities for determination of element
present is permissible.
4.0 QUALITY CONTROL REQUIREMENTS
4.1 There should exist a system to ensure trace ability of the product from raw
material stage to finished product stage.
4.2 Quality Assurance Plan (QAP) of the product to be submitted as per Guidelines
by vendor in duplicate shall cover the following details-
GUIDE LINES FOR QUALITY ASSURANCE PLAN(QAP)
1. Firm's Name

2. Firm's address

(i) Head Office

(ii) Works/Factory

(iii) PHONE/FAX
3. Applied FOR TYPE OF CONSUMABLES :

4 Quality Policy

5. Valid ISO-9001-2000 Certificate for applied item

6. Organisation Chart showing Key personnel (Name, Designation, Qualification,

Experience, responsibilities)

7. Q.A. Organisation Chart (Name, Designation, Qualification, Experience,

responsibilities)

8. Process Flow Chart /Description of Manufacturing Process

It shall have various stages of manufacturing of Finished Product. Brief Description of
manufacturing of applied items.

9. Format of Inspection Plan of Raw Material, In process, Finished product, packing

material
 7

Format of Sr.9
S. Item Sample Frequency Parameters for Specifica- Acceptance Test Traceability
No. Size Inspection tion Criteria/Value

10. Laid Down Procedure regarding identification of accepted/rejected material

11. Laid down procedure regarding disposal of rejected Material at every stages from raw
materials to Finished Product.

12. Corrective & Preventive Action after rejection of material.

13. Storage Plan for raw material & Finished Product

14. List of Sub vendor & items supplied by them
15. Criteria for selection of vendor
16. List of relevant IRS/IS/AWS/RDSO etc. available

17. Laid Down Procedure for Handling customer complaint

18. Detailed Policy of calibration of equipment/gauges & records.

19. In House Testing facilities available for calibration with the firm

S. Name of Master Make Range Frequency of Traceability to

No. calibration National
Standard
20. Personnel Trained for In-House Calibration
S. Name Qualification Experience
No.
21. Calibration Plan of the items identified for specified calibration in STR/Specification.

S. Measuring Ref.Para of Range/ Frequency In-House/ Out Name of

No. Equipments STR/Specn. Accuracy Source Agency
22. Calibration Plan for other measuring equipment

S. Measuring Equipments Range/ Frequncy In-House/ Out Name of

No. Accuracy Source Agency
23. Process Capability Calculation
24. Signature of quality Control
Incharge on each Page No. of
QAP (X of Y)
 8

4.3
i) All the technical personnel responsible for supervision and handling of products and
quality control activities should have Degree in Mechanical Engineering /
Metallurgical Engineering with a minimum of three (3) years experience and should
be working in the firm as regular employees

ii) Artisan staff like machinist, welder and fitter should have ITI qualification in
respective trade and time to time they should have been imparted training from
recognized institution in the respective trades( Enclose training documents)

iii) All employees should be on regular role.

4.4 The vendor shall have acquired ISO Certification ISO : 9001 : 2000 version in
respect of all the products applied for and the same shall be covered in the
certification.

4.5 There should exist a quality manual of the firm indicating the extent of control over
production and testing.

4.6 The firm should ensure that proper analysis is being done on monthly basis to study
the rejection at various internal stages and it is documented.

4.7 The firm should ensure that all the relevant specifications and IS standards are
available with them.

4.8 The firm should ensure that proper record of complaints received from users
(Railways) is being maintained and corrective action is taken.

4.9 Calibrated quality control measuring equipment/instrument like UTM, Impact testing
machine, Vernier callipers/Screw guage, Tong tester, Weight boxes etc. shall be
used.

4.10 Minimum Qty. specified for up-gradation from Pt-II to Pt-I status as per Annex -II
 9
Annex-I

ANNEXURE TO STR

S.No. STR para Requirement of M&P/T&P as per STR Details of the M&P/T&P available with the firm
no.
Name of M&P/T&P Range / Name of M&P/T&P Model Make Machine Year Range/ Proof of
Capacity of no. of Capacity ownership
M&P/T&P Built

UNDERTAKING OF THE FIRM

“I hereby give an undertaking that if at any time after approval is accorded, some machinery is found deficient without intimation to RDSO, and then it will
be presumed that machinery was not there since beginning and firm’s approval will be withdrawn immediately.’’
Date: Signature
Place:
Name in capitals & Designation
Stamp of the firm Note :
1. Details of M & P should be furnished by vendor in complete as per format given above and also furnish the details of the ownership.
2. It should be mandatory to inform the RDSO through FAX (followed by confirmation copy through courier/speed post )as soon as any machinery is
removed from the firm’s premises (even for repair etc.). RDSO should be informed again, when is brought back and made operational.
3.
Date: Signature
Place:
Name in capitals & Designation

Stamp of the firm

 10

Annex-II

Minimum essential quantity of SAW Wire & Flux to be supplied to be on

part-II list for consideration for up gradation in part-I

Sr. Group of SAW wire & flux Minimum Quantity to be

No. supplied of each class to Zonal
Railways, Production units &
wagon Builders only
1 Group-VIIIA 3,000Kg

2 Group-VIIIB 5,000Kg
 11

Annex-III

GOVERNMENT OF INDIA – MINISTRY OF RAILWAYS

RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, Lucknow -226 011

Questionnaire Form in connection with assessment of indigenous SAW Wire &

Fluxes for Submerged Arc Welding for use on Indian Railways
(Please fill up one form for each brand)

1. Name and address of the

manufacturer

Head Office :

Works/Factory :

PHONE/FAX :

2. Particulars of the brand offered

for Assessment (Please enclose
technical leaflet) :
Name of brand :

2.1 Classes/Grades as per IRSM-

39/01 for which required to be
assessed :

2.2 Code No. as per BIS Specn.

No. & Year :

2.3 AWS Specification & Code :

2.4 Current Conditions

i) Sizes manufactured, current
Conditions with
corresponding grade of flux :
ii) current Conditions with
corresponding grade of wire :

Diameter of Voltage Current range Travel speed

Wire(mm) (Amp)

3.5 Type of wire/Flux:

3. Whether offered for initial

assessment or periodic check :
 12

4. Whether the offered brand is

being checked at periodic
intervals for production control.
If yes, please indicate test results
for minimum two sizes of wire/
properties of flux & weld metal
test results made with to sizes of
corresponding grade of wire.

5. Whether the brand has been

approved by NTH/BIS/LLOYODS
Shipping or other approving
Agency, If yes, submit a copy of
approval Certificate :

6. Whether the brand offered is in

regular production?
If yes, please indicate average
annual production :

7. Price per Kg : Size Rs…..

(for information only)

8. Special characteristics/
recommendation for the brand, if
any :
Note :
1. All the items are to be filled properly. Please write N.A. if not applicable.
Form will be rejected without any further reference.

2. In case of customer complaint or failure to adhere to delivery schedule

causing inconvenience to consignee, appropriate action will be taken
against the firm as per extant DOP, RDSO’s decision in this regard shall
be final.

3. All dispute subject to Lucknow jurisdiction.

It is certified that QAP approved by RDSO is being followed and recipe and
process have not been changed.

Encl :

1. Tech. Leaflet Signature of competent authority

with designation and seal
2. BTC in standard format for wire/
Flux(properties of flux & weld
deposit in combination with
respective grade of wire)
 13 Annex-IV

BTC STANDARD FORMAT FOR

Test Results For SAW Wire
Test No……………….. Dt : …………………
1. Sample Details :

Sample IRS Grade Batch No. Date of Size (mm) Packaging as per Quality of wire & Wire spool
Code of Wire manufacture IRS : M-39-01 ( as per IRS M 39-01)
No./Brand
Wire Wire spool

2. Chemical Composition of wire :

Elements% C Mn Si S P Ni Cr Mo Cu Any other

element
Bare Wire

Specified value as
per IRSM -39/01

3. Cast & Helix : 4. Percentage of copper in coating (by Wt.) :

5. Storage Stability Test 6. Any other test (Pl. Specify

Note : Please fill up all the boxes. Write N.A. if not applicable.

Signature of QC Incharge/Chemist
 14

Annex-V 14
BTC STANDARD FORMAT FOR
Test Results For SAW Flux
Test No……………….. Dt : …………………
1. Sample Details :
Sample IRS Batch Date of Type of Packaging Grade, Brand & Weld Parameters*
Code Grade of No. manufacture Flux ( as per IRS : Size of Wire Used
Voltage Current Travel speed
No./Brand Flux M-39-01) in combination

2. Chemical Composition of weld metal :

Elements% C Mn Si S P Ni Cr Mo Cu Any other
element
As obtained

Specified value as
per IRSM -39/01
3. Mechanical Properties:
a) Multirun All weld :
Properties Radiography/Ultrasonic UTS YS %age El. on %age Charpy impact value (Joule)
IIW Blue/RDSO procedure N/mm2 N/ mm2 5d G.L. R.A. Ind. Values Av. Temp oC
No. MC-4 (min.3 values)
As obtained

Specified value as per

IRSM -39/01
b) Two run weld :
Properties Radiography/Ultrasonic Transverse Tensile Bend Test at 90o using Charpy impact value (Joule)
IIW Blue/RDSO procedure strength 3T mandrel Ind. Values Av. Temp oC
No. MC-4 N/ mm2 (min.3 values)
As obtained

Specified value as per

IRSM -39/01
4. Grain Size 5. Basicity Index 6. Tap density 7. Moisture Content
8. Hydrogen in weld metal (….ml/100gm) 9. Any other test (Pl. specify)
Note : Please fill up all the boxes. Write N.A. if not applicable. *Please indicate the name of RDSO approved wire used.
Signature of QC Incharge/Chemist
15